Detailed Product Description:

1.      Application and Composition

This plant works to produce low-oxygen glossy copper rod in 8mm diameter by means of continuous casting and rolling process, with cathode or red copper scrap as the feedstock.

 

The plant is composed of 1 set or 2 sets of reverberatory furnace with 60-ton capacity, five-wheel casting machine, drive unit, roller shears, straightener and burring unit, shaver, rolling mill, coiler, and electrical control system. If cathode is used, a melting furnace with 16-ton/hour capacity and a 10-ton holding furnace are required.

 

2.      Brief Process Flow

Charging red copper scrap (grade 1 or grade 2) → melting and refining in reverberatory furnace → launder to protect molten copper → ladle → casting machine to get cast bar → roller shears → straightener → burring unit → shaver to treat cast bar → feed-in unit → rolling mill → cooling unit to quench rod → winding unit to pre-shape rod → star coiler to lay rod into coil.

 

3.      Red Copper Scrap as Feedstock

Red copper scrap as the feedstock must be Grade 1 or above Grade 2.

            Copper scrap on excellent grade (Pb<100, Sn<300, Ni<50, Zn<50, Fe<50 and Sb<20) should be clean and non-alloy copper wires free from tin, containing no fragile burned wires.

            Copper scrap on grade 2 (Pb<1000, Sn<800, Ni<150, Zn<300, Fe< 500, Sb<100, S<200) should be small director copper wires without insulation, usually containing telephone wires, copper bus bar with varnish coating or paper insulation, and thick or thin, clean copper bar.

            Feedstock is charged into furnace according to the following proportion:

Scrap on grade 1 at 60% + grade 2 scrap at 40%

 

4.      Main Technical Specifications

4.1. Diameter of rod:              φ8mm

4.2. Capacity:                    14~16tons/hr.

4.3. Weight of coil:                3.0~5.0tons

4.4. Overall dimension of plant:     40×7.8×6.1m (not including melting furnace and cooling water circulation system)

4.5. Weight of plant:                85 tons (not including melting furnace)

4.6. Total power of plant:            600kW (not including melting furnace)

 

5.      Components and Specifications

5.1. 60-ton Reverberatory Furnace

5.1.1. Application:                 melting and refining copper scrap

5.1.2. Type:                      stationary

5.1.3. Rated volume:               60 tons

5.1.4. Fuel:    

5.1.5. Mode of heating:              burning nozzle (2 pieces)

5.1.6. Maximum temperature in furnace: 1400℃

5.1.7. Temperature control:           by adjusting amount of fuel

5.1.8. Charging mode:               manual charging with help of lever

5.1.9. Consumption of fuel:           100-110 m³/t.Cu

Composed of steel structure, bricks, fire door, slagging door and lifting mechanism, gas nozzle, air blower, and pipeline, etc.

 

5.2. Five-wheel Casting Machine (Patent No. ZL00244512.3), 1 set

5.2.1. Diameter of casting wheel:          φ1900mm

5.2.2. Speed of casting wheel:             1.84~2.814rpm

5.2.3. Delivery speed of cast bar:           10.17~13.11m/min

5.2.4. Cross sectional area of cast bar:       2300mm²

5.2.5. Motor:                           5.5kW (AC, variable frequency, speed regulated)

5.2.6. Pressure of cooling water:            0.3~0.5Mpa

5.2.7. Amount of cooling water:            170m³/h

5.2.8. Temperature of cooling water:         < 35℃

Composed of casting wheel, press-down wheel tension wheel, guide wheel, casting ladle, cooler, air blower, dust brush, heater and carbonating device, cast bar taker, guide bridge, carbonating device, drive mechanism, water regulator, pneumatic control system, all of which are mounted on the same base plate except the guide wheel.

 

5.3. Roller Shears, 1 set

5.3.1. Motor:                      15kW (AC variable frequency, speed regulated)

5.3.2. Length of cast bar cutting:       700mm

Composed of AC drive and needle cycloidal reducer two blades are fitted on the wheel of the shears to cut the cast bar in a length of 700mm approximately.

 

5.4. Straightener & Burring Unit, 1 set

Composed of straightener and burring unit, with five wheels for straightener, two of which on upper side and three of which on lower side fitted in alternative positions, the burring unit has four blades to cut off the burr from the cast bar.

 

5.5. Shaver, 1 set

Motor

Shaver works to brush off chips on the surface of the cast bar after the burr is cut off, four shaving rollers are individually driven by motors.

 

5.6. Continuous Rolling Mill (Patent No. ZL200420032401.7), 1 set

5.6.1. Main motor:                  450kW (DC)

5.6.2. Final rolling speed:            10m/sec. (max.)

5.6.3. Final diameter of rod:          Dia. 8mm

5.6.4. Center height of rolling:         902.5mm

5.6.5. Number of stands:             12 No.’s

5.6.6. Two-roller stands:              4 No.’s

5.6.7. Three-roller stands:             8 No.’s

5.6.8. Nominal diameter of roller:       Dia. 255mm

Motorized feed-in device for rolling mill, with drive from the main transmission box, and with pneumatic cylinder to clamp the cast bar and help to feed it into the first stand. 4 pairs of stands with two rollers in 255mm diameter, 2 pairs of stand with vertical rollers, and 2 pairs of stands with horizontal rollers work to roughen the cast bar, while 8 pairs of stands with rollers in Y arrangement work to size the cast bar. The stands have upper drive and lower drive arranged alternatively. In case of overloading during the rolling process, a pin in the safety shaft coupling is cut off to protect the gears and the shaft.

 

5.7. Emulsion Lubrication System, 1 set

5.7.1. Emulsion pump:               80m³/hr, 15kW

5.7.2. Filter:                        GLQ-100

5.7.3. Chiller:                       35m²

   The system is composed of chiller, filter, and two centrifugal pumps. Emulsion is pumped through the centrifugal pump, filter, and chiller into the master pipeline on top of the gearbox, and then flows into the stands via hoses to lubricate the gears, rollers, and inlet and outlet positioners, and finally returns back to the emulsion tank via the return channel on the base of the rolling mill.

 

5.8. Oil Lubrication System, 1 set

5.8.1. Gear pump:                   5.5kW

5.8.2. Working pressure:              0.1~0.3Mpa

5.8.3. Filter:                        GLQ-80

5.8.4. Oil tank:                      5m³     

   This system is composed of oil tank, filter, and two gear pumps. Oil in the oil tank is pumped through the filter into the master pipeline at the back of the gearbox, enters the gearbox through three lines, and from oil nozzles lubricates the gears and rolling bearings by spray. Oil finally returns to the oil tank from the low end of the gearbox.

 

5.9. Coiler, 1 set

   It is composed of cooler, operation platform, clamp and delivery device, guide bridge, circular winder, trolley, and alcoholic water supply system.

5.9.1. Drive unit

   Drive speed:                      10m/sec. (max.)

   Drive motor                       7.5kW (DC)

   Two motorized clamp and delivery, with spring to adjust the pressure. A DC motor drives a clamp roller via V-belt to push the rod forward, while two pairs of gears driving another clamp roller to push the rod simultaneously.

5.9.2. Rod winder

   Coiling diameter:                    2000mm

   Winding motor:                     4kW (AC, variable frequency and speed regulated)

   Rod goes through a worm gear shaft under the thrust of the drive, enters a spiral pipe to be pre-shaped, and then falls into the basket on trolley.

5.9.3. Coiler trolley

   Coiling diameter:                    1800mm

   Height of coiler basket:               1500mm

   Motor for basket rotation:             4kW (AC, variable frequency and speed regulated)

   Two baskets, which are set on the trolley, are driven by a motor via a friction wheel underneath so as to get rod laid down in star pattern. There is an air cylinder underneath the trolley that moves the trolley to change the basket.

5.9.4. Cooling and blower system

   Temperature of alcoholic water:         << 45C°

   Consumption of alcoholic water:         50~80m³/h

   Pressure of alcoholic water:             > 0.5Mpa

   The alcoholic water trough is in four sections, with a master inlet pipe and a master return pipe. At the back of the trough there is a blower trough, and there is pressure meter for each section of the trough, and temperature meter for the inlet master pipe and return pipe.

5.9.5. Alcoholic water supply system

   Alcoholic water pump:                 80m³/h, 37 kW

   Chiller:                             80m²(consumption of water at 100ton/hr.)

   This system is composed of one chiller and two centrifugal pumps. Alcoholic water is pumped by the centrifugal pump through the chiller into the master inlet pipe and the cooling trough, return pipe and finally back into the storage tank.

 

5.10. Electrical Control System, 1 set

5.10.1. Power source:                     3-phase 4-line system, AC, 380V, 50Hz

5.10.2. Control circuit:                    single, AC, 220V

   Including general electrical control, automatic display of temperature of the cast bar, speed synchronization control among the casting machine, drive unit, rolling mill, and coiler. Motor for the rolling mill is controlled by Siemens or ABB DC speed regulator. Control panel, console, and temperature sensors are supplied, and the whole system is jointly controlled by PLC touch-screen, which monitors all parameters in the operation process.

 

1.  Scope of Supply

6.1 60-ton Reverberatory Furnace

6.1.1 Steel structure of furnace

6.1.2 Blocks and bricks, including smoke flue

6.1.3 Fire door, slagging door and lifting mechanism

6.1.4 Burner and pipeline

6.1.5 Air blower and pipeline

6.1.6 Chimney (prepared and erected by user on site)

6.1.7 Charging mechanism (prepared and fabricated by user on site)

6.1.8 Cloth bag treatment system for waste gas and dust (optional by user)

6.1.9 Intelligent intermittent temperature finder (1 set)

6.1.10 Cooling pumps for fire door

 

6.2 Casting Machine

6.2.1 Casting machine, including drive and inner cooler

6.2.2 Press-down device, including over-bridge wheel

6.2.3 Tensioner

6.2.4 Outer cooler, including side cooler

6.2.5 Cast bar taker

6.2.6 Guide bridge

6.2.7 Casting ladle (only shell supplied, refractory lining and spout prepared by user on site)

6.2.8 Main motor, including tachogenerator

6.2.9 Steel tape, 4 pieces, in which 3 for stand-by

6.2.10 Cooling water pumps (170m³/h, 37kW to be prepared by user)

6.2.11 Drainage pumps (100m³/h, 22kW to be prepared by user)

 

6.3  Auxiliary Units

6.3.1 Drive unit (including pneumatic device)

6.3.2 Roller shears

6.3.3 Straightener and burring machine (including pneumatic device)

6.3.4 Shaver (including pneumatic device)

6.3.5 Feed-in unit (including pneumatic device)

 

6.4. Continuous Rolling Mill

6.4.1. Main gearbox

6.4.2. Two-roller stand, 4 sets

6.4.3. Three-roller stand, 8 sets

6.4.4. Lubrication oil supply system (including filtering system)

6.4.5. Emulsion supply system (including filtering system)

6.4.6. Main motor (including tachogenerator)

 

6.5. Coiler

1. Cooling, quenching and blowing device (including alcoholic water cooling system, but tank to be prepared by user)
2. Drive wheel
3. Reducer for coiler
4. Swinger
5. Star coiler (including trolley and rail)

 

1. Electrical Control
2. Operation desk for casting machine
3. Control panel for auxiliary units
4. Operation desk, rectifier panel, and switchgear panel for rolling mill
5. Control panel for emulsion and lubrication oil
6. Operation desk for coiler

 

1. Miscellaneous
2. External water supply system for furnace and casting machine to be prepared by user
3. Compressed air system to be prepared by user
4. Seller to be responsible for supervision of installation and commissioning
5. Seller to supply CD Rom for PLC programming and list of easy-to-wear parts

 

1. Features
2. Five-wheel casting machine has better rigidity, water cooling system and nozzle in rational design so as to achieve better cooling result, easy to adjust, operate and service;
3. In case of power failure, the casting ladle with molten copper in turns automatically to pour the molten copper so that the casting wheel will not be damaged, reducing the loss and saving operation cost;
4. Fiber temperature finder performs automatic check-up, displays temperature of cast bar at time of feed-in, convenient for operators to adjust water flow and perform process control;
5. New creation and breakthrough in terms of speed ratio, compression ratio of rolling mill, and diameter of casting wheel, as compared with those of other suppliers. Better compaction of cast bar at higher speed results in better quality rod particularly good for drawing into small wire;
6. Stainless steel trough used for cooling and quenching system, which is not liable to corrosion caused by alcoholic water, resulting in better effect in cooling and quenching, easy for operators to operate and service, and better glossy finish of rod, without going black when drawn into wire;
7. Pumps for the emulsion lubrication system, oil lubrication system, and alcoholic water system are arranged in such a way that when one is at work, another is for stand-by use;
8. The complete production line and electrical control system are completed at the supplier’s factory, easy to commission due to quick service and quality ensured;
9. Full digital Siemens speed regulator is used in the electrical control system, which works at high reliability but lower operational cost. Programmable controller connects with each speed regulator through communication, and speed of each unit is controlled by the programmable controller to the tachogenerator through communication after calculation, which is able to achieve higher reliability, lower rate of breakdown, higher precision, and easy service and maintenance.

 

1. Commitment

We remain ready to send our personnel to offer services at the request of customers.

 

 

 

                                     

                  natural gas or heavy oil